Method of making composite glass and metal articles



Sep l2, 1950 w. c. GREGORY 295217845 METHOD F MKING COMPOSITE GLASS AND METAL ARTICLES Filed July 26, 1944 'n "W Y' /2 fw. ff 54W l/V/ J (W9/ I n v v v v ,4 A W KQ/, /5 j? 77 /4 22 (57237?9 hmmm ATTORNEY Patented Sept. 12, 1950 METHOD F MAKING COMPOSITE GLASS AND METAL ARTICLES Waylande C. Gregory, Bound Brook, N. J. Application July 26, 1944, ySerial No. 546,609

l. This invention relates to methods of making composite articles, and in particular to such articles, embodying areas or portions of gass, o f suitable color or colorsprovided with internal fractures forming light-reflecting facets or S111'- 'faces imparting to the aforesaid areas or portions live gem-like or jewel-like properties of `great decorative, artistic and aesthetic value.

It is the object of this invention to provide new and improved methods of making articles of the class described above wherein the internally fractured areas 0r portions are secured to bases o r-frames of metal providing added strength and protection therefor and/or facilitating4 fabrication of other objects or articles made up of a plurality of such composite articles as units.

It is a further object of this invention to provide methods of making such articles which possess strength and ruggedness sufficient to t them for numerous and widely varied uses functionally, in addition to their decorative utility.

This application is a continuation-in-part .of my copending application Serial No. 426,584, filed January 13, 1942, which maturedV into U. S. Letters Patent No. 2,357,399, granted September 5, 1944.

These and other, .Oblet's and advantages of the invention will clearly appear from the following description taken with the, accompanying drawing and the appended claims.

ln the drawing: Fig. 1 is a plan view. of. a composite article comprising a composite glassand metal panel, illustrative of `one application of this4 invention;

line 2,-2 in Fig. l;

Fig. 2 is a section taken substantially on thev Fig. Sis an enlarged fragmentary view, in sec-I tion, of the structure shown. in Figs.v l and?,

withcross-hatching emittedffrom theglass layerl or portion in the interest of. clearness;

Fig. 4-is a view, similar to Fig. 3, cfa modification of the-structure shown in Fies- 1, -2 and 3;?.

Fig, 5isa view, similar to Figs. 3 and 4, of a secondmodication. embodying an inset or embedded designY element;

Fig. 6 is a View of another m,delineationem:-z

bQdying lens forming areas ofV glass of thickness ccextensiveawith the thickness-of theyco'mposite article;

vessels orarticle, .suchy asa.` tray;

9 Claims. (Cl. 1Q-79) 12 Fig. 8 is a section taken substantially on the line'8-8 of Fig. 7; v y i Fig. 9 is a fragmentary View in section `illustrating the provision of fmeohanical interlock between the glass andmetal for additional security of attachment;

Fig. l0 is `a plan view, partly in sectiony illustrating application of the principles of this invention to a decorative panel for use, for instance, for constructional purposes; i Fig. 11 is a sectiontaken substantially on the line llf-ll of Fig. l0; and Y 'I Fig. -12 is a vieu/,similar to Fig. 1'1, of another modiiication having alternate metal and internally fractured glass surface areas. In my aforesaid application Serial No.v426,58l4, led January 13,` 1942, 'which matured in U. S. Letters Patent No. 2,357,399,granted September 5, 1944, idisclosurevis made of composite articles constructed'of glass and ceramic material wherein the glass is provided with internal fractures forming light reiiecting facets haphazardlyarranged and extending generally depthwise 'and imparting `great beauty and aesthetic appeal t0 the'articles by Ireason of thesimulation, by the glass, of sheetsrof gems or jewels. Methodsof manufacturing such'articles `are also described and rclaimed therein'. i I This invention*l herein disclosed 'extends the principles ofthe invention described and claimed in the aforesaid application'to other articles and uses, and provides y,methods for accomplishing the aforesaid extension' as hereinafter set forth in detail. l l As s ricwvrly in Figs;j'1-.3. an' article embodying the principlesof this invention may comprise a metal supporter backing sheet or panel il having bonded or 'fused thereto a substantiallyk coevxtensive layer I2 of internally fracturedL vitreous material or glass of substantial depth;

i. e., substantially thicker than'a glaze, enamel or othercoat'ing.' Thefractures It l(Fig. 3) are haphazardly arranged andiormlight reflecting facets withinfthe"= glasslayer l2r which impart to lthe visible `surface 'of the article the appearance ofl an" expanse of gems-or jewels of great; richnessand aesthetic appeal'. The glass may be of any Icolor, either uniform throughout or varied throughout, as desired.l Such an article is suitable for use as` a tile .lor panel where the artistic: or' decorative `gein-like y.qualities thereof' are desirablebut'where'the convenience of lmetal' fabrication'isalso desired.;` :-l v1 I i "While the. interfaceor bonding surface I5 'of the articleillustratedin Figs'. `1^-3is planar, it

may be varied by provision of alternate grooves IG and lands I'I (Fig. 4) or the like, for varying the depth of the sheet or layer of internally fractured glass locally and for controlling the size and disposition of the crystals formed by the fractures which extend generally depthivise of the glass layer and which tend to arrange themselves perpendicular to the interface (see Fig. 1l)

Likewise, suitable ornamental or decorative elements or devices I8 may be interposed substantially at the bonding line or plane I5, between the metal base or base member II and the internally fractured sheet or layer I2 as shown in Fig. 5, or, as will be readily understood, the ornaments or devices I8 may lie completely within the body of the sheet or layer I2, out of contact with the base or base member II. Since these ornaments or decorative devicesare visible only through the sheet or layer I2 with its light reiiecting facets or surfaces I4 and its color or colors, many extremely interesting, varied aesthetic effects may be secured by their use as described above.

A further variation in the effect secured by this composite metal and internally fractured glass construction may be achieved by interrupting the continuity of the base or base member I I at desired intervals or locations by the provision of apertures such as I9 (Fig. 6) whereby portions of the layer I2 are made to extend, at suitable locations, from side to side of the composite article. The lenses formed by the glass within the apertures I9 form light transmitting extensions of the sheet or layer proper I2 mak.- ing possible the transmission of light into, and through, the layer or sheet I2. Any desired symbols, ornaments or devices maybe outlined by these lenses 20 by suitable location of the apertures I9 and formation of the light transmitting lenses 2l) therein, as hereinafter described.

While the above description relates to substantially flat, sheetlike articles, it is of course to be understood that the principles of this invention are adapted also to trays, bowls, cups and the like such as the illustrative vessel shown in Figs. 7 and 8. That vessel comprises a cup or tray 2| of metal, with a base or bottom wall 22 and continuous flange or side wall 23. Within the recess formed by the bottom wall 22 and side wall 23, a layer or sheet 24 of internally In order to enhance the security of attachment of the sheet or layer 24 to the vessel 2|, the side Wall or ange 23 may be grooved (Fig. 9) to form an inwardly directedannular flange 25 enga.,- ing a complementary groove 26 formed in the sheet or layer 24 during fusing orbonding. Likewise, when this construction is used the layer or sheet 24 may be formed (with or without its internal fractures) independently` from the vessel or body 2I, with the peripheral groove or channel 2B formed therein, then inserted in the interior of the vessel 2| before the flange 25 is formed therein, and the flange 25 thereafter formed in the side wall 23, for instance, by spinning. The latter step conforms the inwardly directed flange 25 so closely with the groove 26 in the sheet or layer 24 as firmly and securely to connect the glass sheet or layer 24 and the metal vessel 2l together. If the ilayeror sheet 24 was not internally fractured when secured to the vessel 2I, localized thermal shock may then be applied, as hereinafter described, to form the fractures therein.

While the object or vessel 2| (Figs. 7-9) is of relatively light construction capable of production by stamping, drawing, and/or spinning, the principles of the invention are readily adaptable to generally similar metal bodies of substantially greater wall thickness and Weight such as the body of the rectangular tray 3i shown in Figs. 10 and ll. The-side walls 32'and end walls 33 are of substantial thickness as is also the bottom Wall 34, and the latter' wall 34 is provided with deep spaced recesses of any suitable size, shape and spacing forming spaced areas of greater depth than the depth of the sheet or layer 24 as a whole and the depth of these areas being varied because of the inclination of the sides of the recesses 35. In other words, the internally fractured glass in the recesses 35 forms a series of geometric extensions off'the sheet proper 24.

Since the fractures or'facets I4 extending from the back or unexposed surfaces of the glass arrange themselves substantially normal to the 111,1- derlying metal surfaces, generally speaking, the angles of the light reiiecting surfaces or facets formed thereby may be rather closely controlled by the use of such recesses, etc., to vary the size of the crystals formed by the fractures I4 which size varies, generally, with the depth of the glass as well as with the angles of the facets thereof as described above.

As shown in Fig. 12, the walls 32 and 33 may be omitted from the tray 3| and a structure formed which is particularly adapted to use as a tread member, block, or tile and which comprises a metal body 34 provided with spaced recesses 35 containing decorative bodies 24 ofinternally fractured glass with gem-like light reiecting properties. In this article, a part of the tread surface is glass but the surrounding surfaces are metal.

It will, of course, be understood that the composite bodies described above may be provided with any suitable protective coatings such as glazes, lacquersclear varnishes when desired.

It is, likewise, to be understood that the use of rsuitable glass-metal' bonding aidssuch as ground coats or iiuxes applied to the bonding surfaces or interfaces is comprehended where the nature of the materials makes such use desirable or necessary. y l

While the above description relates, generally, to the structure of the composite articles to which this invention relates, methods of production are set forth in detail hereinafter.

In making the above described composite articles, and similar articles, an area or layer of glass is rmly secured to a metal base, vplate 01j backing member. After the attachmentofvth'e glass body or layer to the metal, the above described internal fractures or cracks are formed in the glass without destruction of, or impairment of, the glass-metal bond.

In order to secure iirm attachment or bonding of the glass to the metal, the metal sheet and the glass or glass-forming material are united at or near the fusing temperature of glass whereby the bonding occurs by reason of fusing of the glass to the metal.

In the following claims the terms glass and vitreous material are to be broadly interpreted as including prei'lred or fritted glass, raw 'glass' or glass-forming materials convertible to'inolten glass bythe heat of fusion or bonding, or mix-2 tures of such frittedglass, rawrglass or glasssin forming materials in any. suitableproportions;

convertible by the heat of fusion tozfusiblefmolten" glass. This glass willbond'to (i. e., fuse with) the metal base or base member and thus become sonrmly. secured thereto, or integrated there.-

with thatinternal crackingfor fracturezof'- the:

glass may occur subsequently by reason of. lofcalized applicationof thermal shock, or. by reason of differential shrinkage upon cooling, withouty destruction of the bond between the glassrand bonded to (i. en fused =to) the metal.y The fus` ing-.temperature will of course be maintainedfor sufficient time to eifect complete fusion.

dep'endently of the heating ofthe metal andthe metal base, backing plate or'vesseL the base-or vesselfheated to the desired temperature, and the molten glass then placedthereonor therein.-

.Where the article is of sheet like form i.V e.. unprovidedv with side wallsfor upstanding `anges (Figs. 1 6) independent means, not shown,.suchn asremovable Walls or vframeszof refractory ma-A terial', metal or wood may -be "provided forl maintaining the glass. when moltem: upon the metal sheet, plate orbackingat desired depth.

Where such means comprises metal it may be provided with suitable known-cooling means for maintaining its rtemperature below glass-metal bonding temperature. comprises refractory or ceramic material it may be broken away and the surfaces of the glass layer-ground or otherwise finished after the glassmetal bonding has occurred.`

'If .the use of ground coatingslor uxes ar'eidefsirable or necessary, they'will be appliedto'th'e interfaces or Ybonding surfacestof'the metal either before the metal is heated or after themetal is heated and before the glass is applied,depend ingfupon the nature of the ground coating or flux.

=zeneral1y, the metal chosenias a base'forpsu'ch articles-is such that its coefficient' of expansion diiers `sufficiently from that of the glass' to cause the differenti-al glass-metal shrinkage to overcome the cohesion` in the glass, upon cooling, induce fracture strains in the glass without however breaking or impairing the glass-'metal bond. In such cases cooling of the composite article from glass-metal fusing or bonding temperature will be :followed by the production in the glass of the above described light reflecting facet forming cracks or fractures In other cases, the composite article may be heated to suitable temperature (two hundred or more degrees Farenheit above normal room temperature, for instance) and localized fracture producingT strains induced therein by the localized application of suitable cooling media such as cool fluids or contact with -a blanket or other agent carrying such media.

Where it is desired to produce an article embodying one or more design elements at or adjacent the interface "such as I8 (Fig. 5) this element may `be applied to the base Il before it is heated or inserted in the glass thereon while the glass is molten.

While many metals may be used in forming the metal base member, backing or sheet to which the glass layer is attached, I prefer to use those If the aforesaid meansl i Alternatively molten glass may be prepared 'ine havingfusion temperatures above. i): degrees. Fagnmorepreferably 'above 1'500. degreesl Finirr view .of the comparative fusingY points. of. various glasses -andr metals asaset forth. in the .following tables of approximateffusion' points ortemperatures. 1

, Fusion point, Metal: degrees Aluminum '1217;7" Silver 1760.9 Brass 187050 Gold 1945.5 Copper '1981'.4' Cast iron (White) 2075.0 Cast iron (grey) 2230.0." sten 2372.0 Wrought iron 2732.0.' `Nickel 264K() -P1atinum' 319110' Whileglasses of widely varying compositions may be used in the practice of this invention, glasses which have been found quitefsatisf-actory are those glasses of the low melting type, gen-- erally called common glass? `such as: lead borate glass with a melting point of `.855 F. (approx.) sodium-potash-silicate glass with a`A melting point of 950 F. (approx.) lead-potash-- silica glass with a melting point vof 1200 F.. (upproxg or, medium glasses suchfas: calcium-sodium-silicate glasses with melting pointsslightly above 120,0o F.

Of course, in. combining any .ofV the',VV above: glasseswith anyof. theabove metals, a rather' wide latitudev isfpermissible soflong as the.v haphazardly arranged internal lightrefiectingfacets maybe formed inthe glass andadequateglassmetal-bond'besecured in the nnishedproduct.

From theabove description itwill clearlyvappearthat I vhave provided new and improved. methods of making composite articles of glass: andmetal embodying great decorativevalue and' having widely varying applications, which are`r susceptible Vof production with .ease and: 'economy' from relatively cheap materials asx'hereinv described and hereinafterclaimed. l

`It is of courseto be'understoodthat the-above description is merely'illustrative-and ini nowise:

limiting andrthatl desire to comprehend Within this invention such .modifications as are included claim. as .i new-.and desire to secure bynLetters Patent is:

1. The method of making a composite glass and metal article which comprises, forming a metal base with a recess therein, casting in said recess a body of glass substantially thicker than a glaze and inducing in said glass body internal stresses causing internal fractures therein forming light reflecting facets imparting a jewel-like quality to said glass body.

2. The method of making a composite glass and metal article which comprises, forming a metal base with a recess therein, casting in said recess a body of glass substantially thicker thanr a glaze while fusing said glass body to said base, and applying thermal shock to said glass body for inducing in said glass body internal strains causing internal fracture therein producing light reflecting facets haphazardly arranged therein and imparting a jewel-like quality to said glass body.

3. The method of making a composite glass and metal article which comprises, providing a or normal melting.

metal base, `placing on said base material` con-v reflecting facet forming fractures imparting vto,

saidglass layer a gem-like quality.

4.] The method of making a composite glass and metal article which comprises, providing a metal base member with a recess therein, placing in,y said recess materials convertible to molten glass at the fusion temperature of glass, heating saidvbase and said glass forming material at least tothe fusion temperature of glass to form molten glass and fuse it in the form of a glass layer in said recess, and so cooling said base and said glass-layer as to form therein light reflecting facet forming fractures haphazardly arranged and imparting to said glass layer a crystalline gem-like quality.

' 5. The'method of making a composite glass and metal article which comprises, providing a metal base'member, treating a surface of said base member with a glass-metal fusion facilitating agent,'placing on'said surface glass forming materials convertible to molten glass above the fusion temperature of glass, heating said base and said glass forming material at least to the fusion temperature of glass to form molten glass and fuse it in the form of a glass layer to the aforesaid surface of said base, and so cooling said base and said glass layer as to form therein light reflecting facet forming fractures imparting to said glass-layer a crystalline quality.

6. The method of forming a composite glass and metal article which comprises, providing a metal base member, heating said base member to ajtem'perature approximating the fusing temperature of glass, applying molten glass to said base member at said temperature to form a glass layer thereon, and'cooling said member to induce therein fracture 'forming strains for forming therein light reflecting facets imparting t said glass a jewel-like appearance.

7. The methodof forming a composite glass and metal article which comprises, providing a metal base member, treating a'surface of said base member with a glass-metalfusion promoting agent, heating said base member to a temperature approximating the fusing temperature of glass, `applying molten glass to the treated lll surface of said base member at said temperature to form a glass layer thereon, and applying thermal `shock to a portion at least of said glass layer to induce therein fracture forming strains for forming therein'light reflecting facets imparting tosaid glass a jewel-like crystalline appearance.

8. The method of making a composite glass and metal article which comprises bonding to a metal base member a layer of glass substantially thicker than an ena-mel coating by the following steps: bonding molten glass to said metal base member, vsaid metal base member and glass being near the Vfusion temperature of the glass, cooling the composite glass and metal base member and applying thermal shock until internal cracking of the glass occurs without destroying the bonding between the glass and the metal base member.

9. The method of making a composite glass and metal article which comprises bonding to a metal base member a layer of glass substantially thicker than an enamel coating by the following steps: bonding molten glass to said metal base member, including the application of bonding material between the glass and metal base member, said metal base member and glass being near the fusion temperature of the glass, cooling thev composite glass and metal base member and applying thermal shock until internal cracking of the glass occurs without destroying the bonding between the glass and the metal base member.

' WAYLANDE C` GREGORY.

REFERENCES CITED The following lreferences are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 273,371 Lindsley Mar. 6, 1883 1,556,364 'Smith Oct. 6, 1925 1,594,940 Goodridge Aug. 3, 1926 1,603,552 Middendorf Oct. 19, 1926 1,646,468 Warga Oct. 25, 1927 1,654,401v Bernheim Dec. 27, 1927 1,960,121 Moulton May 22, 1934 2,071,294 Branson Feb. 16, 1937 2,073,254 Redman Mar. 9, 1937 2,357,399 Gregory Sept. 5, 1944 FOREIGN PATENTS Number Country Date 522 Great Britain 1899 

